Sunline RV Forum
Sunline User Photos

Go Back   Sunline Coach Owner's Club > Technical Forums > Repairs and Maintenance
Click Here to Login

Join Sunline Club Forums Today


Reply
 
Thread Tools Search this Thread Display Modes
Old 04-21-2015, 08:42 AM   #1
Senior Member
 
vcrt's Avatar
 
Join Date: Aug 2006
Location: Maryland
Posts: 789
SUN #37
vcrt
Intermittent brake operation problem solved

I've had this problem with my brakes on and off for several years. I checked all of the grounds, all of the connections and the wiring on both my TV and trailer with no success. In desperation, I decided to bring it to a shop that does truck and trailer repairs. To make a long story short, he had the TV and the trailer in the shop on several occasions, replaced the brake controller and the receptacle at the rear bumper, cleaned the terminals on the battery, and replaced some of the wiring under the dash. He said everything was fine and when I took it out again, same problem.
Last spring, just as I was about to put the trailer away for the winter, I was driving over some bumps in the road and noticed that just as the trailer axles passed over the bumps, the brakes started to work, then went out. I said, there has to be a problem with the wiring at the axle, so last week, getting the trailer ready for this year's camping, I rolled it up on blocks to give me room to get under it (those older Sunlines sit real low you know) and with the brake pedal depressed, I shook the wiring. That's when I heard the brake buzzing stop and start on the front axle. I went to my local NAPA store and picked up some two lead trailer wiring:


and used the old wire to pull the new one through the holes in the axle, siliconing the entry and exit points to keep the wire from wearing through on the steel edges of the holes.
Once I had the old wire out of the axle, I could see the problem:

That's the wire that was about mid-way inside the axle tube.
Now, I'm not so sure it was a good idea to pull the new wire through the axle tube like the factory did, because apparently any slack in the wire will cause a chafing against the inside of the axle tube. As it rusts, it probably becomes more of a hazard to the insulation on the wire. Of course, the wire I've replaced it with is now double insulated, so it will be years before that ever becomes a problem, but I think I'll wire tie the wire to the other axle when I do that one.
Hopefully, this might save some headaches for anyone with a similar problem on an older trailer.
Rich
__________________

__________________
1992 T-2470 (now residing in South Carolina)
Current Sunline-2007 Solaris 2499
2018 Silverado 1500 w/Max Trailering pkg.
vcrt is offline   Reply With Quote
Old 04-21-2015, 09:49 PM   #2
Moderator
 
JohnB's Avatar
 
Join Date: Nov 2006
Location: Ohio
Posts: 10,165
SUN #89
JohnB is on a distinguished road
Hi Rich,

You have just described the text book issue with the wires in the axle tube. In many cases the wires insulation becomes brittle and cracks away as well as the rub through.

I redid mine and put it on the outside strapped behind the axle. (not in front to get hit with weeds, brush etc.) when I changed my axle tubes, the insulation on the old wires was real "crispy"

Here is my post on this
Independent Brake Wire Feed Upgrade

Good job on finding your problem. And yes the new wire will last longer.

John
__________________

__________________
Current Sunlines: 2004 T310SR, 2004 T1950, 2004 T2475, 2007 T2499, 2004 T317SR
Prior Sunlines: 2004 T2499 - Fern Blue
2005 Ford F350 Lariat, 6.8L V10 W/ 4.10 rear axle, CC, Short Bed, SRW. Reese HP trunnion bar hitch W/ HP DC

Google Custom Search For Sunline Owners Club
JohnB is online now   Reply With Quote
Old 04-22-2015, 05:56 AM   #3
Senior Member
 
vcrt's Avatar
 
Join Date: Aug 2006
Location: Maryland
Posts: 789
SUN #37
vcrt
2009? That's probably about when my brake problems started and all I had to do was search "Brake problems-JohnB" or something like that and I could have saved myself headaches, time and the expense.
Hey, I have an idea, if you know what procedures you've documented over the years, could you post an index?
Anyway, thanks for the reply John, I'm going to have to remember this for any other issues that come up, seems you've already been there with many of them! What seemed like a mystery to me involved a pretty simple solution once I got educated.
Rich
__________________
1992 T-2470 (now residing in South Carolina)
Current Sunline-2007 Solaris 2499
2018 Silverado 1500 w/Max Trailering pkg.
vcrt is offline   Reply With Quote
Old 04-22-2015, 03:01 PM   #4
Senior Member
 
Gene's Avatar
 
Join Date: Jan 2009
Location: Rhode Island
Posts: 1,515
SUN #768
Gene is an unknown quantity at this point
If you use the plastic ties make sure they are not too tight, they can cut through the insulation.
__________________

Gene & DW Ginny
2002 Sunline T-2363
2008 Toyota 4-runner 4wd 4.7L V-8
Reese Dual Cam straightline - P3 Brake controller
Gene is offline   Reply With Quote
Old 04-27-2015, 09:16 PM   #5
Senior Member
 
vcrt's Avatar
 
Join Date: Aug 2006
Location: Maryland
Posts: 789
SUN #37
vcrt
Just to confirm, we were camping last weekend about an hour away and the brakes worked with every depression of the pedal!
Like I said, this problem has been here for years, but I'm now happy to say that it's fixed!
Rich
__________________
1992 T-2470 (now residing in South Carolina)
Current Sunline-2007 Solaris 2499
2018 Silverado 1500 w/Max Trailering pkg.
vcrt is offline   Reply With Quote
Old 04-29-2015, 09:58 PM   #6
Moderator
 
JohnB's Avatar
 
Join Date: Nov 2006
Location: Ohio
Posts: 10,165
SUN #89
JohnB is on a distinguished road
Great!!! Can't beat a good set of "working" brakes...
__________________

__________________
Current Sunlines: 2004 T310SR, 2004 T1950, 2004 T2475, 2007 T2499, 2004 T317SR
Prior Sunlines: 2004 T2499 - Fern Blue
2005 Ford F350 Lariat, 6.8L V10 W/ 4.10 rear axle, CC, Short Bed, SRW. Reese HP trunnion bar hitch W/ HP DC

Google Custom Search For Sunline Owners Club
JohnB is online now   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Intermittent brakes aaron Repairs and Maintenance 4 04-17-2012 05:12 AM
120 Volt issue - now solved frodothree Repairs and Maintenance 4 02-14-2011 07:00 AM
Converter operation question awellis3 Repairs and Maintenance 3 06-10-2010 11:40 AM
Water Heater Operation MOKID Repairs and Maintenance 21 04-12-2009 04:09 PM
Believe I solved mystery of leak in my Que. CaptKen Sunline Que 5 02-16-2009 09:29 PM


» Featured Campgrounds

Reviews provided by

Disclaimer:

This website is not affiliated with or endorsed by Sunline RV or any of its affiliates. This is an independent, unofficial site.


Copyright 2002- Social Knowledge, LLC All Rights Reserved.

All times are GMT -6. The time now is 01:40 PM.


×